Photochemical etching is used for producing extremely detailed metal parts. In other words, photoetching, a technique that applies photographic as well as chemical techniques to attain micron-level precision. Amongst the choice of metals, nickel is one of the widely used metals in photochemical etching. It is resistant to corrosion, has very good mechanical strength, and is capable of handling excessive heat. All these features make nickel photochemical etching develop elaborate patterns at a fast and effective pace.
In this article, we are going to discuss the nickel photochemical etching process in depth, its characteristics, benefits, and usage.
What is Nickel Photochemical Etching?
Nickel photochemical etching is a process that uses chemical processes in order to form nickel sheets into intricate patterns with high accuracy. Compared to conventional processes, nickel photochemical etching is quick, stress and distortion-free, and a non-contact process. Therefore, this process does not alter the natural properties of nickel. Moreover, the other processes, such as stamping, are time-consuming and expensive.
By using a photochemical etching machine, prototype fabrication can be accomplished in days instead of months. Some of the benefits of nickel photochemical etching over conventional processes are:
- It does not involve costly tools.
- Precise patterns can be achieved without nickel deformation.
- This process can attain ±0.015 mm accuracy.
Nickel Vs Other Metals in Photochemical Etching
Different metals, like stainless steel, brass, copper, etc, are employed for photochemical etching, but they don’t react the same way in the photochemical bath. TMNetch works with brass, copper, nickel, aluminum, and other metals. Let’s compare the characteristics of different metals to nickel for photochemical etching:
Nickel Vs Stainless Steel
Stainless steel is highly corrosion-resistant, which significantly slows the etching process. Also, commonly used concentrations of enchants like ferric chloride (30-40%) are too mild for steel, hence they require stronger concentrations. Nickel can achieve finer features and sharper edge resolution as compared to stainless steel.
Nickel Vs Brass
Brass, an alloy of copper and zinc, etches faster than nickel but requires a more controlled process to avoid over-etching. Nickel alloy photochemical etching offers superior corrosion 0
resistance, but brass has a lower cost.
Nickel Vs Copper
Copper has a very fast etching rate. This causes undercutting and limits the achievable features. As compared to other metals, copper has a conductivity of (~59.6 MS/m) that is higher than nickel.
Advantages of Nickel Photochemical Etching
High Precision
Traditional manufacturing methods can cause rough surfaces and undefined edges. During the nickel photochemical etching process, the material is removed evenly, which allows for the creation of multiple identical parts simultaneously on a single sheet.
Cost Effective
Traditional manufacturing requires:
- Expensive Tools
- Punches
- Dies
This adds up the cost. These processes remove material as chips, so there is a lot of wastage.
Bur-free And Stress-free
Photochemical etching produces totally smooth edges because mechanical force is not used in this process. Hence, you do not need any further finishing operations.
Durability
After photochemical nickel etching, nickel’s inherent corrosion resistance is preserved. In fact, chemical etching increases durability by removing rough areas where corrosion may begin. .
Corrosion Resistance
When exposed to air, nickel can form a thin, stable layer of oxide on its surface. This process is called passivation. Under normal conditions, it prevents oxidation and chemical attack. Hence, nickel photochemical etched parts are long-lasting and maintain their precision even in harsh environments.
Physical Properties
Nickel is dense, hard, and ductile. Hence, it can maintain structural integrity in the creation of intricate patterns with precise details.
High-Temperature Resistance
Nickel has a melting temperature of 1,455°C, which allows it to maintain mechanical properties and stability at extreme temperatures. This high temperature resistance makes photochemical etching nickel parts suitable for different industries.
Step-by-Step Nickel Photochemical Etching
Here is how the nickel photochemical etching process is carried out:
- First, clean nickel sheets are checked for defects or impurities that would impact etching quality
- A coat of light-sensitive resist is applied evenly over both surfaces with spray, dip, or lamination techniques
- Next, the resist is exposed with photographic artwork with UV light to imprint the desired pattern on the material
- A developer solution dissolves unexposed resist areas, leaving protected and unprotected areas
- Then, it is soaked in a hot etchant bath where the naked nickel erodes away, creating the final shape
- Lastly, any remaining photoresist is removed, and the finished nickel parts are cleaned thoroughly
Applications Of Nickel Photochemical Etching
Nickel photochemical etching provides a wide range of industries with precision and durability needs:
- Electronics & Electrical: Circuit boards, EMI/RFI shielding components, electrical contacts, heating grids, and battery current collectors
- Aerospace & Defense: Lightweight structural components, fuel injection screens, turbine blades, sensor housings, and precision mechanical elements
- Medical & Biomedical: Surgical instruments, implant components, microfluidic devices, and diagnostic equipment parts, because nickel is biocompatible
- Industrial Uses: Chemical processing hardware, precision sieves and filters, decorative name tags, and vehicle sensors
The process is best at producing elaborate patterns, high mesh screens, and involved geometries that cannot be achieved using manufacturing processes.
TMNetch uses advanced photochemical etching to produce high-performance nickel components. We specialize in delivering high-performance nickel components with the consistent and fast delivery of high-quality products, and TMNetch addresses this challenge head-on:
- Advanced Technology: With the latest photochemical etching techniques, TMNetch produces nickel parts with razor-sharp edges and consistent quality.
- Proven Expertise: TMNetch has an ISO 9001 certificate and has been operating for years to provide quality service to industries with stringent requirements.
- Catalyzed Development: With a 3-day turnaround for both prototype and full production, your parts get to market faster.
- Versatility: TMNetch also photochemically etches stainless steel, brass, and copper, taking the hassle out of sourcing custom shims, gaskets, encoder discs, surgical blades, and more.
- Precision for Challenging Uses: From micro medical to aero components, you get the precision, durability, and dependability you need—always.
For any project that requires specialized nickel etching, TMNetch is the go-to company. Get in touch with us so that we can talk about your needs and show you the advantages of our photochemical etching service.
FAQs About Nickel Photochemical Etching
What is nickel photochemical etching?
It is a process that involves precision manufacturing using light-sensitive chemicals and controlled etching to strip away material from sheets of nickel, producing intricate shapes and patterns with very fine accuracy and smooth edges.
What is the photochemical etching process?
The photochemical etching process is a production method that merges photography and chemistry. It uses UV light to transfer patterns onto metal via photoresist, followed by chemical solutions eating away the unprotected areas to create precise parts.
Can you etch nickel with ferric chloride?
Yes, ferric chloride, which is the most common etchant for chemical etching, can be used to etch nickel. However, the process is a bit slower and needs heating.
What is the etchant for pure nickel?
Various solutions can be used to etch pure nickel. Common etchants for pure nickel include ferric chloride, nitric acid, hydrochloric acid, and hydrogen peroxide.
Conclusion
Nickel photochemical etching provides unparalleled accuracy, strength, and flexibility in producing intricate metal parts for various industries. From electronics to aerospace use, this state-of-the-art manufacturing process provides superior results where conventional techniques lack the capability.
TMNetch will transform your design ideas to precise nickel parts, using state-of-the-art photochemical etching technology with time-tested expertise to overcome your most challenging manufacturing needs.
